Senior Mechanical Design Engineer (Defence)

About the role

Design rugged, mission‑critical hardware for the Australian Defence Force, taking concepts through qualification to production.

Key responsibilities

• Lead mechanical design of enclosures, structures, mechanisms and thermal solutions for harsh‑environment defence systems.
• Build fully toleranced SolidWorks models, assemblies and drawings, applying GD&T, DFM and DFA across machining, sheet metal, fabrication, moulding and additive processes.
• Perform stress, thermal, shock and vibration analysis and manage tolerance stacks.
• Apply systems engineering practices – requirements, ICDs, traceability, trade studies and V&V.
• Take designs through environmental qualification (MIL‑STD‑810, MIL‑STD‑461) and present at SRR, PDR and CDR with defence customers and prime contractors.
• Mentor graduate and mid‑level engineers and review their work.

Required profile

• Degree in Mechanical, Mechatronics or Aerospace Engineering.
• 8+ years mechanical design experience, including 3+ years in defence, aerospace or other regulated industry.
• Australian citizen able to obtain Baseline security clearance (NV1 preferred).

Required skills

• Advanced SolidWorks (large assemblies, sheet metal, weldments, PDM).
• GD&T, DFM and DFA expertise.
• Stress, thermal, shock and vibration analysis.
• Knowledge of MIL‑STD‑810 and MIL‑STD‑461 qualification standards.
• Systems engineering experience.
• FEA tools such as ANSYS or Abaqus (optional).
• Model‑based systems engineering tools like Cameo or DOORS (optional).